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Texas Technology Showcase
17 - 19 March 2003Houston, TX
Overview
• Who Is Kawasaki Gas Turbines?• What Causes NOx?• How Can We Control NOx?• Field Results• Summary
Kawasaki Gas Turbine History•1943 Built First Aircraft Gas Turbine Engine•1950’s Service Operations - US Military•1972 Started Development of Industrial Gas Turbines Engines•1974 First S1A-01 (200 kW) Gas Turbine Engine•1977 First Gas Turbine Generator Set Delivered•1979 First Mobile Gas Turbine Genset Delivered•1984 First Co-generation System Delivered•1988 First Cheng-cycle Co-generation System Delivered•1988 Developed M1A-13 Gas Turbine (High Efficiency) Engine•1993 Developed M7A-01 Gas Turbine (High Efficiency) Engine•1995 Developed M1A-13D with Dry Low NOx System•1997 Over 5,000 Gas Turbine Engines Delivered•1999 Ceramic Gas Turbine 302, World Record Efficiency 42.1%•2000 Introduced Catalytic Combustion - World’s Cleanest Turbine•2001 Introduction Of L20A•2002 Over 7,000 Gas Turbine Engines Delivered
More To Come!!
Kawasaki Aircraft Turbines
Risk Share PartnerPratt & WhitneyGERolls RoyceEtc
Kawasaki Aircraft Turbines
Pratt & WhitneyF100
F-15 EagleF-16 Falcon
PW4000Airbus A300/A310/A330Boeing B747/767/777
V2500Airbus A319/A320/A321MD-90
Kawasaki Industrial Turbines
Kawasaki Industrial Turbines
• GPB07D 650 kWe• GPB15D 1434 kWe• GPB15X 1423 kWe• GPB60D 5265 kWe• GPB70D 6500 kWe• GPB180D 17,000 kWe
Overview
• Who Is Kawasaki Gas Turbines?• What Causes NOx?• How Can We Control NOx?• Field Results• Summary
NOx Caused By High Temperatures
140
120
100
80
60
40
20
0
2200 2400 2600 2800 3000 3200
Reaction Temperature
Temperaturerequired forturbine Inlet
Temperaturerequiredfor flame
1200 1300 1400 1500 1600 1700 °C
°F
NOx (ppm)
Overview
• Who Is Kawasaki Gas Turbines?• What Causes NOx?• How Can We Control NOx?• Field Results• Summary
Kawasaki’s Combustion Technology
•Dry Low Emissions (DLE)•Catalytic Combustors
Kawasaki’s Combustion Technology
•Dry Low Emissions (DLE)•Current “State Of The Art”
Kawasaki’s Combustion Technology
Dry Low Emissions (DLE) Design Concept•Lean, Pre-mixed Combustion•Multiple Fuel Nozzles•Fuel Nozzle Staging
Kawasaki’s Combustion Technology
DLE Combustor
Kawasaki’s Combustion Technology
DLE Burner Assembly
Kawasaki’s Combustion Technology
•Guaranteed NOx Emissions With DLE
•Less than 25ppm On Larger Machines
•Less than 14ppm On Smaller Machine
•Low NOx power range - 85 to 100% load
Kawasaki’s Combustion Technology
• Catalytic Combustors
Kawasaki’s Combustion Technology
• Catalytic Combustion– In Development Since 1982– ASME Paper Published 1987– Verified Module Durability 1999– Development Complete 2000– First Commercial Order 2000– Delivered First Commercial Units 2001– Demonstrated In Practice 2002
Flame Combustion System
Exhaust NOx~ 25 ppm
Fuel
350 oC
1800 oC
1300 oC
Bypass Air
Drive TurbineCompressor
Catalytic Combustion System
Air
Preburner Fuel
350 oC
Exhaust NOx < 2.5 ppm
Drive TurbineCompressor
Main Fuel
1300 oC
1300 oC
Catalyst Module
Catalytic Combustion System
Control Systems (not shown)
Catalytic Combustion System
Preburner Module– Keeps catalyst in
operating window– Allows engine start-up– Source of NOx
Catalytic Combustion System
Pre-mixer Improves catalyst fuel
and air uniformity to prevent higher temperature regions in catalyst
Catalytic Combustion System
Burn Out Zone–Complete combustion
of remaining fuel (homogenous combustion)
–Complete CO and UHC burnout
Catalytic Combustion System
Bypass System–Increases load
turndown capability–Keeps catalyst in
operating window
Catalytic Combustion System
Catalytic Combustion SystemTraditional Approach
Catalyst surface temp rapidly approaches 1300 oCAt 1300 oC, damage to catalyst will occur
– Noble metal vaporization– Loss of surface area
Temperature(oC)
CH4 / AirMixture
Surface
Gas
1300
800
350
• Higher wall T (designlimits max wall T)
• High outlet gas T
• High activity• Low lightoff T• Designed for low wall T
Sufficient time to:• Complete CH4 combustion• Complete UHC and CO burnout
Surface
All of fuel
All of airInlet
catalystOutlet
catalystHomogeneous
combustion
Tad
TemperatureGas
Catalytic Combustion System
Catalytic Combustion System
Preburner provides required catalyst inlet temperatureCatalyst fuel injector produces a uniform fuel/air mixture for the catalystHigh post catalyst temperature oxidizes CO to < 10 ppmBypass and dilution air provides required turbine inlet temperature
CompressorPr
ebur
nerCat alyst Burn out
zoneTurb ine
Fuel
Inje
c tor
330°C630°F
450°C840°F
1300°C2370°F
1010°C1850°F
Bypass/dilution air
Catalytic Combustion SystemIntegral Heat Exchange Limits Catalyst Temp
Bulk flow
Boundary layerCatalyst
Foil substrate
Boundary layer
Bulk flow
ProductsReactants Rxn heat
Rxn heat
Ts = Tin + ² Tad
2
• Solid cross-section essentially isothermal • Equal heat transferred to catalyzed and non-catalyzed channels • Maximum conversion = 50% • Maximum wall temperature = Tin + ² Tad • Example: Inlet gas T = 700°C (1290°F) Tad = 1300°C (2370°F) non-IHE wall T = 1300°C(2370°F) IHE wall T = 1000°C (1830°F)
12
Catalytic Combustion System
PdO Pd + O2High Temp
Low Temp
12
Catalyst designed to control its own temperature:
Active form Inactive form
Catalytic Combustion System
Overview
• Who Is Kawasaki Gas Turbines?• What Causes NOx?• How Can We Control NOx?• Field Results
– Silicon Valley Power– Sonoma Development Center
• Summary
Field Results - Silicon Valley Power
Field Results - Silicon Valley Power
Performance Criteria Results
Operating Hours > 14000
NOx emissions < 2.5 ppm (corrected to 15% O2)
CO emissions < 6 ppm (corrected to 15% O2)
VOC emissions < 2 ppm
Reliability1 > 98%
Reliability2 > 99%
1 Total turbine engine and catalytic combustor system reliability2 Catalytic combustion system reliability
RAMD: Reliability, Availability, Maintainability, Durability
Field Results - Sonoma Development Center
Field Results - Sonoma Development Center
0
10
20
30
40
50
0 20 40 60 80 100
Load (%kW)
Emis
sion
s (p
pm) _
NOx
HC
CO
Field Results - Sonoma Development Center
“We’re obviously within the legal limits as far as the BAAQMD is concerned and it reads down as far as it needs to. But we would like to be able to read it exactly so everybody can see what we’re doing.”
Mary Lavin, Environmental SpecialistSonoma Development Center
Field Results - Sonoma Development Center
“About the only problem is that we don’t have another one sitting right next to it.”
Ron Johnson, Chief Engineer Sonoma Development Center
Overview
• Who Is Kawasaki Gas Turbines?• What Causes NOx?• How Can We Control NOx?• Field Results• Summary
Summary
Turbines With Catalytic Combustion• No “Black Magic”• Known Maintenance and Repair Requirements
VERY Low Exhaust Emissions • Similar To Fuel Cells• 70 - 100% Load
Completely Environmentally Friendly• No SCR Required (No Ammonia Storage)• No Oil Changes• No Coolant Required
Summary
How clean is clean???– Industry Example– Environmental Example
SummaryEquivalent NOx - 100% Load, 2.5 PPM Guarantee
Natural Gas Fuel, ISO Conditions
0.000
0.050
0.100
0.150
0.200
0.250
20.000 30.000 40.000 50.000 60.000 70.000 80.000 90.000
Total Efficiency (%)
Equi
vale
nt N
Ox
(lbs/
MW
-hr)
Eq. NOx (lbs/MW-hr) NOx Lim. (lbs/MW-hr)
Kawasaki GPB15X Equivalent NOx Output
Proposed Equivalent NOx Limit
Summary
Summary
A single lightning strike makes as much NOx in an instant as aKawasaki Gas Turbine with catalyticcombustion does in an entire year!!
Summary
• Catalytic Combustion Available• Next Generation Of Combustion
Technology• Low Risk• Cost Effective• In Production
Summary
“Our third goal is to promote energy independence for our country, while dramatically improving the environment.”
George W. Bush
State-Of-The-Union Energy Independence Goals
Kawasaki Gas Turbines - AmericasA Division Of Kawasaki Motors Corp., U.S.A.
Grand Rapids, MI616 949 6500
www.kawasaki.com/gtd
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